Compact reduction agent doser for use in an scr system of an internal combustion engine

ABSTRACT

An SCR system for use with an IC engine includes a reduction agent doser and a catalytic reactor. The reduction agent doser includes a tubular housing with an inside diameter. A target plate is positioned crosswise in the housing and terminates at a distance from the inside diameter of the housing. The target plate directs a flow of exhaust gas in a radially outward direction. A baffle is positioned crosswise in the housing downstream from the target plate. The baffle terminates at the inside diameter of the housing and includes a center opening for directing a flow of exhaust gas in a radially inward direction. A diffuser plate is located downstream from the baffle. The diffuser plate terminates at the inside diameter of the housing. A catalytic reactor is directly coupled with a downstream side of the reduction agent doser.

FIELD OF THE INVENTION

The present invention relates to internal combustion engines, and, more specifically, to exhaust aftertreatment of such engines.

BACKGROUND OF THE INVENTION

A vehicle such as a work machine in the form of a construction work machine, an agricultural work machine or a forestry work machine, typically includes a power unit in the form of an internal combustion (IC) engine. The IC engine may either be in the form of a compression ignition engine (i.e., diesel engine) or a spark ignition engine (i.e., gasoline engine). For most heavy work machines, the power unit is in the form of a diesel engine having better lugging, pull-down and torque characteristics for associated work operations.

The Environmental Protection Laws enacted in the United States decades ago have imposed ever increasing limits on permitted emissions from IC engines. The diesel engine has enjoyed a position of being a durable and fuel efficient engine thus making it the engine of choice for commercial, industrial and agricultural use. As emissions limits have been lowered, it becomes increasingly more difficult to meet the standards with a diesel engine.

Diesel engines provide advantages in fuel economy, but produce and emit both NOx and particulates during normal operation. When primary measures (actions that affect the combustion process itself, such as exhaust gas recirculation and engine timing adjustments) are taken to reduce one, often the other is increased. Thus, combustion conditions selected to reduce pollution from particulates and obtain good fuel economy tend to increase the output of NOx. Current and proposed regulations and legislation present significant challenges to manufacturers to achieve good fuel economy while at the same time reducing the emission levels of particulates and NOx.

In order to meet such requirements or restrictions, a method known as selective catalytic reduction (SCR) has been used for reducing the emission of NOx. The SCR method consists of injecting gaseous ammonia (NH3), ammonia in aqueous solution or aqueous urea, or ammonia supplied from an ammonia generator using a solid source of ammonia such as ammonia carbamate or ammonia carbonate, into the exhaust gas system of the compression ignition engine as a reduction agent. When the temperature of the exhaust gas stream is above a reaction temperature, for example a temperature above 160° C. for aqueous urea, the reduction agent undergoes a hydrolysis process and is decomposed into ammonia and CO₂. As the exhaust gas stream is passed through the SCR catalyst, the gaseous ammonia reacts with the NOx to reduce the NOx to molecular nitrogen. This reduces or limits the NOx emissions from the compression ignition engine.

In an SCR system as described above, the ammonia is typically provided by evaporating and decomposing a urea-water solution that is now referred to as a diesel emission fluid (DEF). In a typical SCR system, the DEF is sprayed onto a mixer in an exhaust pipe and a further length of exhaust pipe (typically 0.5 m to 1.0 m) is provided after the mixer to complete the mixing before entering the SCR catalytic reactor. An SCR system of this conventional design requires considerable space and adds cost.

SUMMARY OF THE INVENTION

The invention in one form is directed to an IC engine including an engine block with a plurality of combustion cylinders. An exhaust system receives exhaust gases from the combustion cylinders. The exhaust system includes an exhaust manifold and an exhaust conduit for conducting the exhaust gas from the engine. An emissions control system includes a reduction agent doser and a catalytic reactor. The reduction agent doser has a tubular housing with an inside diameter. A target plate is positioned crosswise in the housing and terminates at a distance from the inside diameter of the housing. The target plate directs a flow of the exhaust gas in a radially outward direction. A baffle is positioned crosswise in the housing downstream from the target plate. The baffle terminates at the inside diameter of the housing and includes a center opening for directing a flow of the exhaust gas in a radially inward direction. A diffuser plate is located downstream from the baffle, and terminates at the inside diameter of the housing. A catalytic reactor is coupled with a downstream side of the reduction agent doser.

The invention in another form is directed to a reduction agent doser for use in an emissions control system for an IC engine. The reduction agent doser includes:

a tubular housing with an inside diameter;

a target plate positioned crosswise in the housing and terminating at a distance from the inside diameter of the housing, the target plate directing a flow of exhaust gas in a radially outward direction;

a baffle positioned crosswise in the housing downstream from the target plate, the baffle terminating at the inside diameter of the housing and including a center opening for directing a flow of exhaust gas in a radially inward direction; and

a diffuser plate located downstream from the baffle, the diffuser plate terminating at the inside diameter of the housing.

The invention in yet another form is directed to an SCR system for use with an IC engine, including a reduction agent doser and a catalytic reactor. The reduction agent doser includes a tubular housing with an inside diameter. A target plate is positioned crosswise in the housing and terminates at a distance from the inside diameter of the housing. The target plate directs a flow of exhaust gas in a radially outward direction. A baffle is positioned crosswise in the housing downstream from the target plate. The baffle terminates at the inside diameter of the housing and includes a center opening for directing a flow of exhaust gas in a radially inward direction. A diffuser plate is located downstream from the baffle. The diffuser plate terminates at the inside diameter of the housing. A catalytic reactor is directly coupled with a downstream side of the reduction agent doser.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an embodiment of an SCR system of the present invention for use with an IC engine; and

FIG. 2 is a sectional view of the reduction agent doser shown in FIG. 1, taken along line 2-2.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, there is shown an embodiment of an IC engine 10 which includes an SCR system 12 for reducing exhaust emissions to the ambient environment. IC engine 10 is presumed to be a diesel engine in the illustrated embodiment, and includes an engine block 14 with a plurality of combustion cylinders 16. Engine block 14 is shown with four combustion cylinders 16, but may have any suitable number of combustion cylinders depending upon the engine, such as two, six, or eight cylinders. IC engine 10 also includes an intake manifold 18 and an exhaust manifold 20 which are each in fluid communication with the plurality of combustion cylinders 16. Intake manifold 18 receives and provides a source of combustion air to the plurality of combustion cylinders 16. Exhaust manifold 20 receives exhaust gases from the plurality of combustion cylinders 16 and discharges the exhaust gases through an exhaust conduit 22 to the downstream SCR system 12.

SCR system 12 generally includes a reduction agent doser 24 and a catalytic reactor 26. Reduction agent doser 24 is assumed to be a urea doser in the illustrated embodiment. Reduction agent doser 24 includes a tubular housing 28 in which are disposed a reduction agent injector 30, target plate 32, baffle 34, and diffuser plate 36. The structure and arrangement of reduction agent doser 24 is such that the various components thereof cause the exhaust gases to flow in radially outward and radially inward directions, thereby providing a sufficient latency period for proper mixing of the DEF and exhaust gas within reduction agent doser 24 prior to flowing into catalytic reactor 26. This reduces the area required by reduction agent doser 24 while still maintaining adequate mixing of the DEF with the exhaust gases.

Reduction agent injector 30 injects a fluid reduction agent, such as DEF, toward target plate 32. The particular configuration and impingement angle of reduction agent injector 30 may vary, depending upon the application.

Target plate 32 generally provides an impingement surface for the DEF which is mixed with the exhaust gases. Target plate 32 is positioned crosswise within housing 28 and terminates at a distance from the inside diameter of housing 28. For example, target plate 32 may be supported by a plurality of stand-off rods 38 which centrally locate the circular disk-shaped target plate 32 within the circular inside diameter of housing 28. The particular diameter of target plate 32 may be selected according to desired flow characteristics, flow rate, etc. Moreover, it is possible that target plate 32 need not be a circular, disk-shaped plate but, rather, have another shape for a particular application, such as octagonal or hexagonal.

Baffle 34 is likewise positioned crosswise with housing 28 at a location which is downstream from target plate 32. Baffle 34 terminates at (i.e., extends to) the inside diameter of housing 28 and includes a center opening 40 for directing a flow of the exhaust gas in a radially inward direction. In the embodiment shown, baffle 34 has an annular shape and center opening 40 is a concentrically positioned, circular opening with an inside diameter which is smaller than the outside diameter of target plate 32. Thus, as shown in FIG. 1, the exhaust gases first flow in a radially outward direction around target plate 32 and then in a radially inward direction to pass through center opening 40.

Diffuser plate 36 is located downstream from baffle 34 and also terminates at the inside diameter of housing 28. Diffuser plate 36 functions to distribute the exhaust gases mixed with DEF in a more uniform manner across diffuser plate 36. Referring to FIG. 2, a portion of baffle 34 has been fragged out to illustrate the perforations within diffuser plate 36. These perforations may be of the same diameter, or may vary across the face of diffuser plate 36. Likewise, diffuser plate 36 need not have pass-through perforations but, rather, may be differently configured to diffuse the flow of exhaust gases and DEF, such as by using a lattice structure, etc.

Catalytic reactor 26 may be of conventional design, and is directly coupled to the downstream side of reduction agent doser 24. Catalytic reactor 26 preferably has a flow path diameter which is approximately the same as the inside diameter of housing 28.

During operating, exhaust gases are transported from exhaust manifold 20, through exhaust conduit 22, to SCR system 12. A DEF is injected against target plate 32 at a desired flow velocity and impingement angle. The DEF and exhaust gases flow in a radially outward direction around target plate 32 and then in a radially inward direction toward center opening 40 of baffle 34. This generally serpentine-type flow path provides a sufficient latency period for adequate mixing of the DEF with the exhaust gases. The mixed DEF and exhaust gases are diffused by diffuser plate 36 and flow into catalytic reactor 26 where a catalytic reaction occurs in known manner.

In the embodiment of SCR system 12 shown and described above, the mixing of the DEF with the exhaust gases occurs because of the mixing time associated with the longer flow path. To further assist in mixing of the DEF with the exhaust gases, an optional heater (such as a resistive type heater) 42 (shown in dashed lines in FIG. 2) may be provided at the rear or face of target plate 32.

Having described the preferred embodiment, it will become apparent that various modifications can be made without departing from the scope of the invention as defined in the accompanying claims. 

1. An internal combustion (IC) engine, comprising: an engine block including a plurality of combustion cylinders; an exhaust system for receiving exhaust gases from said combustion cylinders, said exhaust system including an exhaust manifold and an exhaust conduit for conducting exhaust gas from the engine; and an emissions control system, including: a reduction agent doser having a tubular housing with an inside diameter, a target plate positioned crosswise in said housing and terminating at a distance from said inside diameter of said housing, said target plate directing a flow of the exhaust gas in a radially outward direction, a baffle positioned crosswise in said housing downstream from said target plate, said baffle terminating at said inside diameter of said housing and including a center opening for directing a flow of the exhaust gas in a radially inward direction, and a diffuser plate located downstream from said baffle, said diffuser plate terminating at said inside diameter of said housing; and a catalytic reactor coupled with a downstream side of said reduction agent doser.
 2. The IC engine of claim 1, wherein said catalytic reactor has a flow path diameter which is approximately the same as said inside diameter of said housing.
 3. The IC engine of claim 1, wherein said target plate is a circular disk-shaped plate, and said baffle is annular shaped with a circular center opening.
 4. The IC engine of claim 1, wherein said catalytic reactor is directly coupled to a downstream side of said reduction agent doser.
 5. The IC engine of claim 1, wherein said target plate is a heated target plate.
 6. The IC engine of claim 1, wherein said diffuser plate is a perforated plate.
 7. The IC engine of claim 1, wherein said emissions control system includes a reduction agent injector for injecting a fluid reduction agent toward said target plate.
 8. The IC engine of claim 1, wherein said reduction agent doser is a urea doser.
 9. A reduction agent doser for use in an emissions control system for an internal combustion (IC) engine, said reduction agent doser comprising: a tubular housing with an inside diameter; a target plate positioned crosswise in said housing and terminating at a distance from said inside diameter of said housing, said target plate directing a flow of exhaust gas in a radially outward direction; a baffle positioned crosswise in said housing downstream from said target plate, said baffle terminating at said inside diameter of said housing and including a center opening for directing a flow of exhaust gas in a radially inward direction; and a diffuser plate located downstream from said baffle, said diffuser plate terminating at said inside diameter of said housing.
 10. The reduction agent doser of claim 9, wherein said target plate is a circular disk-shaped plate, and said baffle is annular shaped with a circular center opening.
 11. The reduction agent doser of claim 9, wherein said target plate is a heated target plate.
 12. The reduction agent doser of claim 9, wherein said diffuser plate is a perforated plate.
 13. The reduction agent doser of claim 9, including a reduction agent injector for injecting a fluid reduction agent toward said target plate.
 14. The reduction agent doser of claim 9, wherein said reduction agent doser is a urea doser.
 15. A selective catalytic reduction (SCR) system for use with an internal combustion (IC) engine, comprising: a reduction agent doser including: a tubular housing with an inside diameter; a target plate positioned crosswise in said housing and terminating at a distance from said inside diameter of said housing, said target plate directing a flow of exhaust gas in a radially outward direction; a baffle positioned crosswise in said housing downstream from said target plate, said baffle terminating at said inside diameter of said housing and including a center opening for directing a flow of exhaust gas in a radially inward direction; and a diffuser plate located downstream from said baffle, said diffuser plate terminating at said inside diameter of said housing; and a catalytic reactor directly coupled with a downstream side of said reduction agent doser.
 16. The reduction agent doser of claim 15, wherein said target plate is a circular disk-shaped plate, and said baffle is annular shaped with a circular center opening.
 17. The reduction agent doser of claim 15, wherein said target plate is a heated target plate.
 18. The reduction agent doser of claim 15, wherein said diffuser plate is a perforated plate.
 19. The reduction agent doser of claim 15, wherein said reduction agent doser includes a reduction agent injector for injecting a fluid reduction agent toward said target plate.
 20. The reduction agent doser of claim 15, wherein said reduction agent doser is a urea doser. 